Spring assembly for bedding and furniture



July 28, 1964 F. A. NACHMAN, JR., ETAL 3,142,071 smug ASSEMBLY FOR BEDDING AND FURNITURE Filed Nov. 22, 1960 \xfii A Li 7 A A FIG. 3

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United States Patent 3,142,071 SPRING ASSEMBLY FOR BEDDING AND FURNITURE Fred A. Nachman, Jr., Chicago, and Arthur E. Rose, Des

Plaines, Ill., assignors to Nachman Corporation, Chicago, Ill., a corporation of Illinois Filed Nov. 22, 1960, Ser. No. 71,086 6 Claims. (Cl. 248) This invention relates to a spring assembly formed of a multiplicity of coil springs interconnected one with the other in the assembly, and it relates more particularly to such a spring assembly characterized by the combination of the desirable attributes of a spring portion comprising units of compressed springs contained within cells or socks of fabric material and of a spring border or edge portion comprises a plurality of spring coils the terminal coils of which are directly connected to the border frame members of the spring assembly.

The former referred to spring portion will hereinafter be identified as of the Marshall type. The Marshall type spring portion is more fully described in the United States Patent No. 2,790,979. The latter referred to spring portion will hereinafter be referred to as the Wuest edge described in United States Patent No. 2,885,693. With particular reference to the Marshall type spring assembly, it has been found that spring assemblies can be produced which are characterized by a satisfactory resiliency but which are incapable of maintaining a desirable fiattened surface in use. One particular location which is subject to excessive deformation is in the edge portions since the number of springs available to resist load in the edge construction is naturally less than in the inner portion of the spring assembly.

It is an object of this invention to produce a composite coil spring assembly embodying the advantages of a Marshall type unit with an improved edge construction, but in a manner wherein the edge can be tied into the Marshall type unit to maintain a desirable flattened construction in the surfaces of the spring assembly and wherein one construction enhances the effectiveness of the other to provide a composite spring assembly which is characterized by improved stiffness, resiliency and support, while also providing improvement in appearance and strength.

These and other objects of this invention will hereinafter appear and for purposes of illustration but not of limitation an embodiment of the invention is shown in the accompanying drawings, in which:

FIG. 1 is a fragmentary plan view of the novel structure according the concepts of this invention;

FIG. 2 is a front view of the structure of FIG. 1; and

FIG. 3 is a front sectional view of the structure of FIG. 1, taken along the line 3--3 thereof showing one of the cell-type spring units partially exposed.

With reference to these drawings, it is seen that the novel multiple coil assembly which constitutes the subject invention comprises a plurality of coil springs arranged in rows to provide an internal spring portion (which is indicated generally by the reference numeral 2) and an external spring portion (which is indicated generally by the reference numeral 4).

The internal spring portion 2 comprises a plurality of so-called Marshall type spring units 6, such as the type shown in United States Patent No. 2,790,979,- arranged in crosswise and lengthwise rows. While the structure has been illustrated with the spring units 6 spaced apart from each other as far as possible while still remaining in contact, it should be understood that any suitable geometrical arrangement of these units is within the confines of the invention, such as an off-set staggering of any or of all of the rows. The Marshall units 6 comprise individual 3,142,071 Patented July 28, 1964 coil springs 10 confined within individual cells or socks 11 formed of textile material 12, such as burlap or other open-meshed fabric of soft and pliable material. In the construction of such a unit, a plurality of individual coil springs 10 may be arranged in an elongate row 13 and wrapped with the textile fabric 12 which is then stitched lengthwise, as at 14, between the separated springs to provide a series of interconnected cells in a row 13, after which the ends of the fabric are secured together as by stitching after the spring coils have been compressed to form cells of uniform lengths which are dimensioned to be considerably less than the lengths of the spring coils when in their extended or relaxed condition. Thus, an elongate row 13 of spring coils individually housed in interconnected cells in side-by-side relation are provided, the length of the row of cells corresponding preferably to the length of the internal spring portions desired for the cushion assembly. Instead, separate cells containing compressed coil springs confined therein may be formed and arranged in side-by-side relation in the rows as desired. Additional rows 15, 16 and 17 of the type described are positioned crosswise in contacting relation with each other to build up the desired width of the spring assembly. The assembled individual cells may be mutually interconnected, as by the bail tie Wires 18, or they may be interconnected by any other conventional intertying means such as strings or helical chords passed about adjacent terminal portions of the spring coil.

The external spring portion 4 comprises a plurality of coil springs 20 of saddleor hourglass-shape. The springs 20 are perimetrically disposed about the borders of the internal spring portion 2 and are interconnected thereto by any conventional means, such as by clips, bail wires 22 or the like. This assembly of Marshall units 6 and saddle coils 20 is provided with upper and lower border frame members 26 and 28, respectively, which extend completely about the assembled coil springs with the upper border frame member 26 adjacent the outer edges of the upper terminal coils 27 of the coil springs 20 and with the lower border frame member 28 correspondingly adjacent the outer edges of the lower terminal coils 29 of the coil springs 20. The border frame members may be formed of rigid resilient material such as of plastics, wood, or the like, but it is preferred to form the border frame members as spring metal members of heavier cross section than the Wires forming the coils of the coil springs. While the border frame members are preferably formed with a rectangular cross section, elements of round or of other shape may be employed.

In accordance with the practice of this invention, an improved assembled relation for the border frame members and the assembled coils is achieved by turning the outermost portions of the terminal coils about the border frame members for direct engagement therewith. By virtue of this practice, an assembly having markedly improved characteristics relative to the strength, rigidity, and resilience of its edge portion is achieved by the arrangement of the border frame members to extend as chord members across the terminal coils of the spring inwardly a substantial distance from the outer edges-of the terminal coils of the outermost coil springs so that, prior to assembly, the border frame members 26 and 28 overlie a substantial portion of the terminal coils of the coil springs to locate the border frame members substantially in vertical alignment with the spring coils 35 of smaller dimension making up the remainder of the coil spring 20. This brings the border frame members more directly in operaframe member, as illustrated at 40, more completely to tie-in the border frame member with the spring coils and into alignment with the concentration of coils of the coil springs, as distinguished from being offset therefrom. This provides for greater resistance to deformation of the border frame members and the edge portions of the spring assembly, thereby to provide the effect heretofore secured by the objectionable use of auxiliary spring elements, such as spring arms arranged between the border frame members to stiffen the edge portion of the assembly.

If the border frame members were tied in with the outer edge portions of the terminal coils of the outermost coil springs 20 in offset relation from these springs, the edge portions of the spring assembly would be too soft and too easily depressed under load conditions. It is more desirable to provide for greater resistance to depression at the edge portions, for greater comfort and use, and for improved spring action. At the same time, the coil springs are tied in more completely with the border frame members in a manner which resists displacement and in a manner which is capable of maintaining a desired assembled relation notwithstanding the direction of the applied force in use. It will be apparent further that the location of the border members in a more effective relationship with respect to the coil springs of the assembly will provide for a better reaction to load from various directions and for greater resilience with respect to a return to normal position from a loaded condition.

The invention is further characterized in that the springs 20 are dimensioned to have a normal or extended length which is greater than the length of the textile cells 11 such that when the coil springs are tied into the border frame members 26 and 23 the external spring coils will naturally assume a length which corresponds to the length of the textile cells. When the spring assembly is fabricated according to this design, the composite is characterized by level internal and external spring portions 2 and 4. Although such a leveled structure presents a particularly desirable commercial embodiment for the spring assembly by virtue of a more pleasant appearance and of a more comfortable base for the user, it has been further found that this unique compression of the external spring portion 2 to the level of the internal spring portion 4 results in an assembly which is characterized by as much as 20 percent greater resistance to deformation for a given load by comparison to a similar construction wherein the springs of the adjacent spring sections are originally of equivalent height. Thus, the internal spring portion 2 contains coil springs which are confined in a compressed state by enclosure represented by the textile cells 11 while the external spring portion 4 is formed of free coil spring 20 which are reduced to a compressed state by virtue of the unique interconnection with the border frame members 26 and 28. The novel combination of elements provide an assembled relationship wherein the outer coil springs of greater length than in the Marshall unit are reduced to a level with the spring coils forming the Marshall unit and to provide a tensioned relationship throughout.

The novel combination of elements provide an assembled relationship wherein the outer coil springs of greater length than in the body portions of the Marshall units are reduced in height in the assembly to correspond with the height of the compressed Marshall units to provide a uniformly flattened surface throughout the spring assembly, and at the same time, introduce a tensioned relationship within the outer unit as well as within the Marshall unit to effect a different relationship therebetween whereby greater stiifness and resiliency in the edge construction contributes materially to the support in the body portion, while the interconnected Marshall units of the body portion tends to support the edge construction in a manner to enhance the performance of a spring assembly and the appearance thereof.

It will be understood that various changes may be made in the details of construction, arrangement and operation without departing from the spirit of the invention, especially as defined in the following claims.

We claim:

1. A multiple coil spring assembly comprising a plurality of coil springs arranged in rows to form an internal spring portion and an external spring portion bordering the perimeter thereof and means interconnecting said spring portions, said internal spring portion comprising a plurality of coil springs, a cell for each coil spring formed of textile material and dimensioned to have a diameter corresponding generally to the diameter of the coil springs and a length less than the normal length of the coil springs, said coil springs being confined within said cells in a compressed state to form prefabricated units which are separate and apart from each other, and means interconnecting said spring-containing cells aligned in rows to effect an assembled relation, and said external spring portion comprising a plurality of coil springs of saddle-shape which have a normal length greater than the length of the textile cells, a top border frame member and a corresponding bottom border frame member arranged about the coil springs adjacent the top and bottom terminal coils respectively thereof and positioned to extend as chord members across the terminal coils to subdivide said coils into inwardly extending portions and outwardly extending portions, the latter of which are wrapped about the border frame to effect an interconnection therebetween, to compress the external spring coils to a length which corresponds to the length of the textile cell, and to position the border frame members in substantial vertical alignment with the outer edges of the intermediate coils of least diameter in the coil springs of saddle-shape thereby to locate the border frame members in substantial vertical alignment with the major axial forces capable of being developed by the engaged coil springs when said springs are in loaded condition and to provide a coil spring assembly characterized by level internal and external spring portions.

2. A multiple coil spring assembly comprising the combination of an internal spring portion forming the body portion of the spring assembly and an outer spring portion comprising a plurality of coil springs arranged about the perimeter of the body portion and in which the coil springs are dimensioned to have a length greater than the length of the springs in the body portion when in the 'relaxed state, said internal spring portion comprising a plurality of coil springs, 21 cell for each coil spring formed of a resilient material and dimensioned to have a diameter corresponding to the diameter of the coil springs and a length less than the normal length of the coil springs and in which the coil springs are confined in a compressed state, means interconnecting said cells aligned in lengthwise and crosswise rows to effect an assembled relation and means interconnecting the outer springs of said internal spring portion with the coil springs arranged about the perimeter thereof, a top border frame member and a bottom border frame member aranged about the coil spings in the external spring portion adjacent the top and bottom terminal coils respectively and positioned to extend as a chord across the terminal coils to subdivide the coils into an inwardly extending portion and an outwardly extending portion, the latter of which is wrapped about the border frame members to effect an interconnected relationship therebetween whereby the border frame members are aligned vertically with the main concentration of spring coils of the coil springs in the external spring portion.

3. A multiple coil spring assembly as claimed in claim 2 in which the cells forming the body portion of the spring assembly comprise prefabricated units which are separate one from the other.

4. A multiple coil spring assembly as claimed in claim 2 in which the coil springs in the external spring portion comprise coil springs of saddle shape and in which the top and bottom border frame members are vertically aligned 5 6 with the outer portions of the coils of smallest dimension spring assembly are interconnected one to another by in the saddle-shaped coil springs. stitching.

5. A multiple coil spring assembly as claimed in claim 2 in which the cells forming the bottom portion of the References Cited in the file of this patent spring assembly are interconnected one to the other by 5 UNITED STATES PATENTS means of clips operatively engaging the adjacent portions of the terminal coils of the adjacent coil springs. 1931744 Taylor 1933 6. A multiple coil spring assembly as claimed in claim 2715435 Rymland 1955 2 in which the cells forming the body portion of the coil 2885693 Wuest May 1959 

1. A MULTIPLE COIL SPRING ASSEMBLY COMPRISING A PLURALITY OF COIL SPRINGS ARRANGED IN ROWS TO FORM AN INTERNAL SPRING PORTION AND AN EXTERNAL SPRING PORTION BORDERING THE PERIMETER THEREOF AND MEANS INTERCONNECTING SAID SPRING PORTIONS, SAID INTERNAL SPRING PORTION COMPRISING A PLURALITY OF COIL SPRINGS, A CELL FOR EACH COIL SPRING FORMED OF TEXTILE MATERIAL AND DIMENSIONED TO HAVE A DIAMETER CORRESPONDING GENERALLY TO THE DIAMETER OF THE COIL SPRINGS AND A LENGTH LESS THAN THE NORMAL LENGTH OF THE COIL SPRINGS, SAID COIL SPRINGS BEING CONFINED WITHIN SAID CELLS IN A COMPRESSED STATE TO FORM PREFABRICATED UNITS WHICH ARE SEPARATE AND APART FROM EACH OTHER, AND MEANS INTERCONNECTING SAID SPRING-CONTAINING CELLS ALIGNED IN ROWS TO EFFECT AN ASSEMBLED RELATION, AND SAID EXTERNAL SPRING PORTION COMPRISING A PLURALITY OF COIL SPRINGS OF SADDLE-SHAPE WHICH HAVE A NORMAL LENGTH GREATER THAN THE LENGTH OF THE TEXTILE CELLS, A TOP BORDER FRAME MEMBER AND A CORRESPONDING BOTTOM BORDER FRAME MEMBER ARRANGED ABOUT THE COIL SPRINGS ADJACENT THE TOP AND BOTTOM TERMINAL COILS RESPECTIVELY THEREOF AND POSITIONED TO EXTEND AS CHORD MEMBERS ACROSS THE TERMINAL COILS TO SUBDIVIDE SAID COILS INTO INWARDLY EXTENDING PORTIONS AND OUTWARDLY EXTENDING PORTIONS, THE LATTER OF WHICH ARE WRAPPED ABOUT THE BORDER FRAME TO EFFECT AN INTERCONNECTION THEREBETWEEN, TO COMPRESS THE EXTERNAL SPRING COILS TO A LENGTH WHICH CORRESPONDS TO THE LENGTH OF THE TEXTILE CELL, AND TO POSITION THE BORDER FRAME MEMBERS IN SUBSTANTIAL VERTICAL ALIGNMENT WITH THE OUTER EDGES OF THE INTERMEDIATE COILS OF LEAST DIAMETER IN THE COIL SPRINGS OF SADDLE-SHAPE THEREBY TO LOCATE THE BORDER FRAME MEMBERS IN SUBSTANTIAL VERTICAL ALIGNMENT WITH THE MAJOR AXIAL FORCES CAPABLE OF BEING DEVELOPED BY THE ENGAGED COIL SPRINGS WHEN SAID SPRINGS ARE IN LOADED CONDITION AND TO PROVIDE A COIL SPRING ASSEMBLY CHARACTERIZED BY LEVEL INTERNAL AND EXTERNAL SPRING PORTIONS. 